Caterpillar Cat 988G Wheel Loader (Prefix BNH) Service Repair Manual (BNH00001 and up)

1
Service Repair Manual
Models 988G Wheel Loader
2
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Product WHEEL LOADER Model 988G WHEEL LOADER
BNH Configuration 988G Wheel Loader BNH00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 988G Wheel Loader Power
Train Media Number -RENR3096-11 Publication Date
-01/05/2011
Date Updated -25/05/2011
i02112056
Torque Converter - Assemble SMCS -
3101-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
A 138-7575 Link Bracket 2
B 1P-0520 Driver Gp 1
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F 1P-0520 Driver Gp 1
F 8T-5096 Dial Indicator Gp 1
Note Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry.
Wiping cloths or rags should not be used to dry
parts. Lint may be deposited on the parts which
may cause later trouble. Inspect all parts. If
any parts are worn or damaged, use new parts for
replacement. Note Apply oil to all of the
bearings before assembly. 1. Check the condition
of the O-ring seals that are used in the torque
converter and torque converter housing. If any
of the seals are damaged, use new parts for
replacement.
3
Illustration 1 g00674989 2. Install five O-ring
seals (96) and three plugs (97) .
Illustration 2
g00674987
3. Install block (95) and four bolts (94) .
Illustration 3
g00674791
4
4. Install seal (71) onto piston (70) .
Illustration 4
g00674790
5. Install piston (70) .
Illustration 5
g00674788
Illustration 6
g00674750
5
6. Install two wear plates (68) and two friction
discs (69) .
Illustration 7
g00674748
7. Install plate (67) and retaining ring (66) .
Illustration 8
g00674744
Illustration 9
g00674747
6
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1. Install clutch adapter (65) and hub (63) to
   turbine (64) .
2. Install 24 bolts (62). The torque for bolts (62)
   is 105 15 Nm (77 11 lb ft).

Illustration 10
g00674727
10. Install bearing (61) .
Illustration 11 g00674725 11. Install O-ring
seal (59) and two plugs (60) .
8

• Illustration 12 g00675696
• Use the appropriate equipment in order to turn
  the housing assembly onto the opposite side, as
  shown.
• Install turbine assembly (64) into housing
  assembly.

• Illustration 13 g00675769
• Install the ring and the plate below bearing (58)
  .
• Install bearing (58) .

9

• Illustration 14 g00675437
• Use the proper equipment in order to handle
  bearing (57) .
• Heat bearing (57) to a maximum temperature of 135
  C (275 F).
• Install bearing (57) onto the outer shaft.
• Note Allow the bearing and the shaft to reach a
  uniform temperature.
• Use a hammer and a punch in order to reset the
  bearing around the inside race of the bearing.
  This will ensure that the bearing is seated
  correctly.
• Use the proper equipment in order to handle seal
  carrier (56) .
• Note Allow the ring and the shaft to reach a
  uniform temperature.
• Heat seal carrier (56) to a maximum temperature
  of 135 C (275 F).
• Install seal carrier (56) onto the outer shaft.

Illustration 15 g00675571 23. Use a hammer and a
suitable punch in order to install pin (55) .
10
Illustration 16
g00674523

1. Install seal (52) .
2. Install two seals (53) .
3. Install retaining ring (54) .

Illustration 17
g00674522
27. Install seal (51) to sleeve (50) .
11
Illustration 18 g00674521 28. Install sleeve
(50) and eight bolts (49). The torque for bolts
(49) is 30 5 Nm (22 4 lb ft).

• Illustration 19 g00674520
• Use the proper equipment to handle race (48) .
• Lower the temperature of race (48) .
• Install race (48) in drive gear (47) .

• Illustration 20 g00674519
• Install drive gear (47) onto housing assembly
  (45) .
• Install 12 bolts (46). The torque for bolts (46)
  is 105 15 Nm (77 11 lb ft).

12

• Illustration 21 g00674514
• Install Tooling (E) in order to housing assembly
  (45) .
• Attach a suitable lifting device and lifting
  slings to housing assembly (45) .
• Use the suitable lifting device in order to
  install housing assembly (45) to outer shaft
  assembly. The weight of housing assembly (45) is
  45 kg (100 lb).

Illustration 22
g00674516
37. Install seal (44) onto piston (43) .
13
Illustration 23
g00674512
38. Install piston (43) .
Illustration 24 g00674510 39. Install two
friction discs (42) and one wear plate.
Illustration 25
g01061078
40. Install plate (41) .
14
41. Install two bolts (25) on the underside of
plate (41) .
Illustration 26 g00674506 42. Install 12 bolts
(38) and impeller (36) to adapter assembly (39).
The torque for bolts (38) is 105 15 Nm (77
11 lb ft).

• Illustration 27 g00674505
• Use the proper equipment in order to handle race
  (37) .
• Lower the temperature of race (37) .
• Install race (37) in impeller (36) .

15

• Illustration 28 g00674507
• Install the ring and the plate below bearing (40)
  .
• Install bearing (40) .
• Install the plate above bearing (40) .

Illustration 29 g00674504 49. Use two persons in
order to install the impeller (36) onto the shaft
assembly. The weight of impeller (36) is 29 kg
(65 lb).
16
Illustration 30
g00674503
50. Install retaining ring (35) .

• Illustration 31 g00674501
• Install the ring and the plate below bearing (34)
  .
• Install bearing (34) .

Illustration 32
g00674499
17
53. Install spacer (33) .
Illustration 33
g01061000

• Illustration 34 g01060995
• Use proper equipment in order to handle stator
  (24) .
• Use a suitable press in order to install adapter
  (30) into stator (24) .
• Install plate (28) and retaining ring (29) onto
  stator (24). Install plate (27) (not shown), and
  retaining ring (26) (not shown) in the opposite
  side of stator (24) .

18
Illustration 35 g00673888 57. Install stator
(24) to carrier assembly (23) .

• Illustration 36 g00673887
• Carefully rotate carrier assembly into the
  upright position. The springs and the rollers
  will hold the stator in place.
• Install Tooling (D) to carrier assembly (23) .
• Attach a suitable lifting device and lifting
  slings to carrier assembly (23) .
• Use the suitable lifting device in order to
  install carrier assembly (23) to the torque
  converter housing. The weight of carrier assembly
  (23) is 132 kg (290 lb).

19
Illustration 37 g01061064 62. Install 36 bolts
(21) and washers (22). The torque for bolts (21)
is 60 7 Nm (45 5 lb ft).

• Illustration 38 g00675572
• Use the proper equipment in order to handle seal
  carrier (20) .
• Heat seal carrier (20) to a maximum temperature
  of 135 C (275 F).
• Install seal carrier (20) onto inner shaft (18) .
• Use the proper equipment in order to handle
  bearing (19) .
• Heat bearing (19) to a maximum temperature of 135
  C (275 F).
• Install bearing (19) onto inner shaft (18) .
• Note Allow the bearing and the shaft to reach a
  uniform temperature.
• Use a hammer and a suitable punch in order to
  reset the bearing around the inside race of the
  bearing. This will ensure that the bearing is
  seated correctly.

20

• Illustration 39 g00673883
• Install Tooling (C) to shaft assembly (18) .
• Attach a suitable lifting device and a suitable
  lifting sling to Tooling (C) .
• Use the suitable lifting device in order to
  install shaft assembly (18). The weight of shaft
  assembly (18) is 17 kg (38 lb).

Illustration 40 g00673879 73. Carefully position
the torque converter onto the side, as shown.
21
Illustration 41 g00673881 74. Install washer
(17), retainer (16), and two bolts (15). The
torque for bolts (15) is 105 15 Nm (77 11
lb ft).
Illustration 42 g00673880 75. Install cover (14)
and six bolts (13). The torque for bolts (13) is
60 7 Nm (44 5 lb ft).
Illustration 43
g00660849
22

1. Position the torque converter upright.
2. Install gasket (10) .
3. Install O-ring seals (11) and (12) .

Illustration 44 g00660847 79. Use Tooling (B) in
order to install seal (9) into retainer (8) .
Illustration 45 g00660846 80. Install retainer
(8) and eight bolts (7). The torque for bolts (7)
is 60 7 Nm (45 5 lb ft). Note It is
necessary to install the torque converter into
the torque converter housing prior to
installation of the idler gear.
23

• Illustration 46 g00665414
• Install Tooling (A) to the torque converter
  housing.
• Attach a suitable lifting device and lifting
  chains to Tooling (A), as shown.
• Use the suitable lifting device in order to
  install the torque converter housing to the
  torque converter. The weight of the torque
  converter housing is 270 kg (600 lb).

Illustration 47
g00665412
84. Install eleven bolts (6) and the washers.
24
Illustration 48
g00665121

1. Install yoke (5) .
2. Install O-ring seal (4) .

Illustration 49 g00665406 87. Install bolt (2)
and retainer (3). The torque for bolt (2) is 240
25 Nm (175 20 lb ft).
Illustration 50
g00674986
25
88. Install two bearings (92) and ring (93) to
idler gear assembly (91) .
Illustration 51
g00675821
89. Install idler gear assembly (91) .
Illustration 52
g00675822

1. Install idler gear shaft (90) .
2. Install bolt (89) and the washer.

26
Illustration 53
g00674982
92. Install O-ring seal (88) to cover (87) .
Illustration 54
g00675823
93. Install three bolts (86) and cover 87.
Illustration 55 g00675717 94. Use the proper
equipment in order to handle bearing cup (85) .
27

1. Lower the temperature of bearing cup (85) .
2. Install bearing cup (85) into the housing.

• Illustration 56 g00675718
• Use the proper equipment to handle bearing (83) .
• Heat bearing (83) to a maximum temperature of 135
  C (275 F).
• Install bearing (83) onto gear assembly (77) .

Illustration 57
g00674959

1. Install plate (82) onto adapter (80) .
2. Install retaining ring (81) .

28

• Illustration 58 g00674957
• Install adapter assembly (80) into gear assembly
  (77) .
• Install retaining ring (79) .

• Illustration 59 g00675719
• Use the proper equipment in order to handle
  bearing (78) .
• Heat bearing (78) to a maximum temperature of 135
  C (275 F).
• Install bearing (78) onto gear assembly (77) .
• Note Allow the bearing and the gear assembly to
  reach a uniform temperature.
• Use a hammer and a suitable punch in order to
  reset the bearing around the inside race of the
  bearing. This will ensure that the bearing is
  seated correctly.

29

• Illustration 60 g00675721
• Install gear assembly (77) and entire shim pack
  (84) .
• If both pump drives were removed, repeat Steps 94
  through 108 for the remaining pump drive.

Illustration 61 g00716568 110. Lower temperature
of bearing cup (75). Install bearing cup (75)
into adapter (73). Ensure that the bearing cup
(75) is seated.
30

• Illustration 62 g00716572
• Note DO NOT install the seals to the adapters at
  this time.
• Use two persons in order to install adapters (73)
  and (77) on the torque converter housing. The
  weight of adapter (73) is 30 kg (65 lb).
• Install seven bolts (72) and six bolts (78). The
  torque for bolts (72) and (78) is 240 40 Nm
  (177 30 lb ft).
• When possible, rotate either the torque converter
  or the outer housing in order to ensure that the
  bearings are properly seated.

Illustration 63 g00675824 114. Use Tooling (F)
in order to check bearing end play. The bearing
end play must be 0.15 0.05 mm (.006 .002
inch). Remove shims (84) in order to attain the
correct bearing end play. 115. Remove the pump
adapters from the torque converter housing.
Illustration 64
g00674954
31

1. Use Tooling (B) in order to install seal (76)
   into adapter (73) .
2. Lightly lubricate seal (76) with oil.

• Illustration 65 g00674953
• Install two O-ring seals (74) on adapter (73) .
• Lubricate the O-ring seals (74) prior to
  assembly.
• Install two O-ring seals and one lip seal on the
  remaining adapter.

• Illustration 66 g00716572
• Install the correct amount of shims (84) to the
  torque converter housing. The correct shim
  thickness was determined in the above steps.
• Use two persons in order to install adapters (73)
  and (77) on the torque converter housing. The
  weight of adapter (73) is 30 kg (65 lb).
• Install seven bolts (72) and six bolts (78). The
  torque for bolts (72) and (78) is 240 40 Nm
  (177 30 lb ft).

32
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1. When possible, rotate either the torque converter
   or the outer housing in order to ensure that the
   bearings are properly seated.
2. Use Tooling (F) in order to recheck the bearing
   end play. If necessary, repeat the above
   procedure.

Illustration 67
g00660841

• 126. Install speed sensor (1) .
• End By
• Install the transmission oil pump. Refer to
  Disassembly and Assembly, "Transmission Oil Pump
  - Install" for the machine that is being
  serviced.
• Install the torque converter outlet relief valve.
  Refer to Disassembly and Assembly, "Relief
• Valve (Torque Converter Outlet) - Install" for
  the machine that is being serviced.
• Install the modulating valve for the torque
  converter impeller clutch. Refer to Disassembly
  and Assembly, "Modulating Valve (Torque Converter
  Impeller Clutch) - Install" for the machine that
  is being serviced.
• Install the modulating valve for the torque
  converter lockup clutch. Refer to Disassembly
  and Assembly, "Modulating Valve (Torque Converter
  Lockup Clutch) - Install" for the machine that
  is being serviced.
• Install the torque converter. Refer to
  Disassembly and Assembly, "Torque Converter -
  Install" for the machine that is being serviced.

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34
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 988G WHEEL LOADER
BNH Configuration 988G Wheel Loader BNH00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 988G Wheel Loader Power
Train Media Number -RENR3096-11 Publication Date
-01/05/2011
Date Updated -25/05/2011
i02071477
Torque Converter (Lockup) - Disassemble SMCS -
3101-015-L7 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
A 138-7575 Link Bracket 2
B 5F-7366 Screw 1
B 3H-0465 Plate 2
B 1P-5546 Crossblock 1
B 5H-7369 Puller Leg 2
B 6B-6682 3/4" - 16 NF Nut 2
B 1P-0520 Driver Gp 1
B 4C-5653 Threaded Adapter 2
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F 5F-7366 Screw 1
F 3H-0465 Plate 2
F 1P-5546 Crossblock 1
35
5H-7369 Puller Leg 2
8B-7551 6B-6682 1P-0520 Bearing Puller 3/4" - 16 NF Nut Driver Gp 1 2 1
5F-7366 Screw 1
3H-0465 Plate 2
1P-5546 Crossblock 1
G 8B-7549 5F-7343 Puller Leg Bearing Puller 2 1
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
5F-7342 Adapter 2
H 1P-0520 Driver Gp 1
J 138-7574 Link Bracket 2

• Start By
• Remove the torque converter. Refer to Disassembly
  and Assembly, "Torque Converter - Remove" for
  the machine that is being serviced.
• Remove the transmission oil pump. Refer to
  Disassembly and Assembly, "Transmission Oil Pump
  - Remove" for the machine that is being serviced.
• Remove the torque converter outlet relief valve.
  Refer to Disassembly and Assembly, "Relief Valve
  (Torque Converter Outlet) - Remove" for the
  machine that is being serviced.
• Remove the modulating valve for the torque
  converter impeller clutch. Refer to Disassembly
  and Assembly, "Modulating Valve (Torque Converter
  Impeller Clutch) - Remove" for the machine that
  is being serviced.
• Remove the modulating valve for the torque
  converter lockup clutch. Refer to Disassembly
  and Assembly, "Modulating Valve (Torque Converter
  Lockup Clutch) - Remove" for the machine that is
  being serviced.

36
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manual if required, please enter the following
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